GB2626748A

GB2626748A - Cartridge and device

Info

Publication number: GB2626748A
Application number: GB2301373.3A
Authority: GB
Inventors: William Owen Smith Charles; Mark Iles Jean-Paul; Joseph William Moloney Patrick
Original assignee: Inlab Ventures Ltd
Current assignee: Inlab Ventures Ltd
Priority date: 2023-01-31
Filing date: 2023-01-31
Publication date: 2024-08-07
Also published as: GB202301373D0; WO2024161103A1

Abstract

There is provided a device cartridge 20 having a casing 22, a wick 24 and a heating element 26, the casing formed of film or sheet material. The casing includes a chamber defining a reservoir for storing a precursor or ingredient, and the chamber holds the wick, and the heating element is arranged in the casing to, in use, enable heating of the wick by the heating element. The camber may include first and second sub-chambers respectively defining a reservoir and a vaporisation chamber. Also disclosed is a kit of parts for making such a cartridge, and a dispensing device including such a cartridge and a mouthpiece.

Description

CARTRIDGE AND DEVICE

The invention relates to a device cartridge and a dispensing device, particularly an inhalation device cartridge and an inhalation device, preferably for aerosol dispensing devices such as, but not limited to, electronic cigarettes and vaping devices.

It is known to use replaceable cartridges in dispensing devices, such as electronic cigarettes and vaping devices.

According to a first aspect of the invention, there is provided a device cartridge comprising a casing, a wick and a heating element, the casing formed of film or sheet material, the casing comprising a chamber, wherein the chamber defines a reservoir for storing a precursor or ingredient, the chamber holds the wick, and the heating element is arranged in the casing to, in use, enable heating of the wick by the heating element.

Forming the casing of a film or sheet material not only results in a compact and lightweight configuration of the device cartridge but also reduces the overall number of parts in comparison to conventional device cartridges, which enables faster and cheaper production and also reduces cost and waste. Furthermore, forming the casing of a film or sheet material results in a ready-to-use device cartridge due to the inclusion of the wick and heating element. Moreover, forming the casing of a film or sheet material results in an inhalation device cartridge having the structural integrity to handle changes in temperature and air pressure without risk of leakage.

Preferably the casing is formed of only the film or sheet material. However, it is envisaged that the casing may instead be formed of the film or sheet material and at least one other material.

It will be appreciated that the film or sheet material may comprise a single material piece or multiple material pieces. The film or sheet material may be a composite material and/or may include one or more laminas and/or may include one or more coatings.

The properties and configuration of the film or sheet material may vary.

Preferably the film or sheet material is impermeable. The film or sheet material may include, but is not limited to, a polymeric material, such as a thermoplastic material, and/or a metallic material, such as aluminium.

In still further embodiments of the invention, the casing may be formed of at least two bonded layers of the film or sheet material. It will be appreciated that the at least two bonded layers of the film or sheet material forming the casing may belong to the same material piece or different material pieces. The bonding of the layers may be carried out using heat sealing, pressure sealing, ultrasonic welding, high frequency welding, fusing or adhesive.

The casing may be shaped and/or sized so that the device cartridge has an asymmetric shape. This makes it easier for a user to insert the asymmetric device cartridge in the correct position and orientation in a dispensing device. In other embodiments, the casing may be shaped and/or sized so that the device cartridge has a symmetric shape.

The wick may vary in configuration so long as the wick is capable of withdrawing the precursor, ingredient or a derivative thereof from the reservoir and transferring the withdrawn precursor, ingredient or derivative to a location for heating by the heating element. The wick and the heating element together function as an atomiser to produce aerosol or vapour from the withdrawn precursor, ingredient or derivative.

The wick is preferably configured so that the precursor, ingredient or derivative is drawn through the wick by capillary action. The wick may be pre-wetted with the precursor, ingredient or derivative.

The wick may be made of a fibrous material. The wick may be made of a porous material. The wick may be made of an absorbent material. The wick may be made from one or more materials such as, but not limited to, cotton, paper and/or silica.

The reservoir may contain an absorbent material, such as a wadding or wick-like material. The absorbent material may be separate from, or form part of, the wick.

The device cartridge may include a single wick or multiple wicks, and may include a single heating element or multiple heating elements.

In embodiments of the invention the heating element may be in direct contact with the wick. For example, at least part of the heating element may be arranged on, around, under and/or in the wick. Alternatively, the heating element may be spaced apart from the wick. In this case the heating element is kept sufficiently near the wick to, in use, enable heating, by the heating element, of the precursor, ingredient or derivative transferred by the wick.

It will be appreciated that the casing is not limited to a single chamber but instead may include a plurality of chambers. Furthermore the or each chamber may be sub-divided into distinct sub-chambers that are in fluid communication with each other. This is made readily possible by the formation of the casing from film or sheet material, which enables the inclusion of any number of chambers and sub-chambers in the casing using the same manufacturing process.

In embodiments of the invention, the chamber may include first and second sub-chambers. The first sub-chamber may define the reservoir for storing an aerosol precursor or ingredient. The second sub-chamber may define a vaporisation chamber.

The wick and/or the heating element may be at least partially arranged in the second sub-chamber. The wick and/or the heating element may be at least partially arranged in the first and second sub-chambers.

Optionally a chamber seal may be formed between the sub-chambers, and the chamber seal may be breakable to fluidly connect the sub-chambers. The purpose of the chamber seal is to prevent accidental leakage or displacement of the precursor, ingredient or derivative from the first sub-chamber prior to the point of intended use and also to prevent ingress of outside air, moisture or water into the first sub-chamber prior to the point of intended use. This is particularly beneficial during manufacture of the device cartridge or transport of the device cartridge, e.g. being carried by a person. Hence, the wick may be kept dry prior to breakage of the chamber seal. This not only maintains the freshness of the device cartridge to the point of intended use and extends the shelf life of the device cartridge but also may permit the use of cheaper or single polymer film or sheet material.

Furthermore, the unbroken seal can act as a seal of quality, freshness or authenticity to, for example, indicate that the precursor or ingredient in the first sub-chamber is supplied by the original manufacturer. This addresses quality and/or safety issues arising from counterfeit device cartridges or from genuine device cartridges that are refilled with a precursor or ingredient not supplied by the original manufacturer.

The chamber seal may be configured in a variety of ways, non-limiting examples of which are set out as follows.

The chamber seal may be broken by direct user interaction with the chamber seal, such as bending, pressing or twisting. Alternatively the chamber seal may be broken when the device cartridge is received inside a housing of a dispensing device, where the house includes one or more features (such as a pin, a protrusion or a bump) for mechanically interacting with the chamber seal.

The chamber seal may be formed of the film or sheet material. Preferably the chamber seal is formed of only the film or sheet material. However, it is envisaged that the chamber seal may instead be formed of the film or sheet material and at least one other material.

The chamber seal may be a frangible seal or a single-use seal. Alternatively the chamber seal may be resealable.

In embodiments of the invention, at least part of the wick may be suspended inside the vaporisation chamber. The wick may be supported at one end to form a cantilever, may be supported at both ends to form a bridge structure, or may be supported at a plurality of points along a length of the wick. This helps to protect the wick from damage during handling of the cartridge.

In further embodiments of the invention, the device cartridge may include a lid that is arranged to close off the vaporisation chamber from the outside of the casing. The lid may be openable to provide access to the vaporisation chamber. The lid may act as a seal of quality, freshness or authenticity. It will be understood that the device cartridge may include multiple lids, each of which is arranged to close off the vaporisation chamber from the outside of the casing.

The lid may be arranged to seal the vaporisation chamber from the outside of the casing. Furthermore, the lid may be a resealable lid.

The lid may include a weakened portion by which the lid is openable. The weakened portion may be or may include, for example, a perforation line, a tear line, a cut line, a thinned portion, a hinged portion or an ablated portion. The weakened portion not only makes it easier to open the lid but also can provide a user with a visual indication of how to open the lid.

The lid may be formed of film or sheet material. Preferably the lid is formed of only the film or sheet material. However, it is envisaged that the lid may instead be formed of the film or sheet material and at least one other material. The lid may be planar or may be non-planar, e.g. shaped as a three-dimensional structure (e.g. an ampoule or a capsule).

The device cartridge may include at least one retention structure configured to locate and retain a position of the wick relative to the chamber. The or each retention structure may be in the form of, for example, a projection, a pin, a groove, a step, a notch, a hole, a slot or a channel. The purpose of the or each retention structure is to ensure that the wick stays in the correct position relative to the chamber so that it can perform its intended function, without requiring manual intervention by the user. The wick may be shaped to permit cooperation of the wick with the or each retention structure in order to locate and retain a position of the wick relative to the chamber.

For example, the wick may be shaped to include, for example, a projection, a pin, a groove, a step, a notch, a hole, a slot or a channel.

The heating element may be combined with the wick to isolate the heating element from the casing. For example, the heating element may be arranged on, around, under and/or in the wick to isolate the heating element from the casing. This allows the use of the wick as a thermal break to thermally insulate the heating element from the casing and thereby limit the heating of the casing by the heating element.

The device cartridge may include one or more support members attached to the casing.

The or each support member may be configured to support the heating element and/or the wick so as to isolate the heating element and/or the wick from the casing. Preferably the or each support member is made from a thermally insulating material.

The device cartridge may include one or more reinforcement members combined with the wick and/or the heating element. The or each reinforcement member acts to maintain the shape of the wick and/or heating element by, for example, increasing the strength or stiffness of the wick and/or the heating element.

The device cartridge may include one or more support structures inside the chamber.

The or each support structure may be in direct contact with the wick so as to reinforce the wick. The or each support structure acts to maintain the shape of the wick and/or heating element by, for example, increasing the strength or stiffness of the wick and/or

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the heating element. The or each support structure may be or may include, for example, a pin, a projection or a bump. The or each support structure may form part of the casing or may be separate from the casing.

Preferably the wick is planar. This provides various benefits to the construction of the device cartridge. In some embodiments of the invention, the wick may be planar, and a thickness of the planar wick may extend perpendicularly to a flat face of the casing. This allows the casing to be shaped to be as flat as possible. In other embodiments of the invention, the wick may be planar, and a thickness of the planar wick extends parallelly to a flat face of the casing. This allows the casing to be shaped to improve how the wick is secured in the device cartridge.

In embodiments of the invention, part of the wick may be arranged to extend out of the casing. In such embodiments, the device cartridge may include a cover covering the part of the wick extending out of the casing. This protects the wick from damage or contamination prior to use. The cover may be operable to uncover the part of the wick extending out of the casing. The cover may be detachably attached to the casing, so that the cover is detachable from the casing (e.g. by tearing or snapping off the cover from the casing) to uncover the part of the wick extending out of the casing.

The detachable cover may be formed of the film or sheet material. In particular, the detachable cover may be initially integrated with the casing but is configured to be detachable (e.g. tearable) from the casing. Alternatively the detachable cover may be formed of a different material from the film or sheet material, e.g. another film or sheet material.

In embodiments of the invention, the device cartridge may include one or more electrical contacts inside the chamber, wherein the or each electrical contact is in electrical contact with the heating element. Preferably the or each electrical contact extends into the chamber from outside of the casing. This enables the electrical connection of the heating element to an external power source outside the casing.

Preferably the film or sheet material is thermoformed film or sheet material.

In further embodiments of the invention, the casing may include one or more weakened sections (e.g. a hinged section, a thinned section, an ablated section) by which the casing may be bent or folded. This not only allows the device cartridge to be reconfigured into a more compact configuration for use in a dispensing device but also increases the number of manufacturing processes, such as thermoforming, that can be used to manufacture the device cartridge.

The device cartridge of the invention may be used in a wide variety of dispensing devices.

One such dispensing device is an inhalation device. Therefore, the device cartridge may be an inhalation device cartridge, and the reservoir may be configured for storing an aerosol precursor. The aerosol precursor may be, for example, a solid aerosol precursor, a gel aerosol precursor or a liquid aerosol precursor. The aerosol precursor may include, but is not limited to: a vaping substance (also known as vape juice, e-juice and e-liquid); nicotine, a cannabinoid, cannabidiol, tetrahydrocannabinol, a psychoactive substance, a non-psychoactive substance and/or a nicotine-free substance and/or a derivative thereof.

According to a second aspect of the invention, there is provided a kit of parts for a device cartridge, the kit of parts comprising a casing, a wick and a heating element, the casing formed of film or sheet material, the casing comprising a chamber, wherein the chamber defines a reservoir for storing a precursor or ingredient, wherein the casing, the wick and the heating element are combinable to form the device cartridge according to any one of the first aspect of the invention and its embodiments.

The features and advantages of the first aspect of the invention and its embodiments apply mutatis mutandis to the features and advantages of the second aspect of the invention and its embodiments.

According to a third aspect of the invention, there is provided a dispensing device comprising a mouthpiece, a housing and a replaceable device cartridge, the device cartridge in accordance with any one of the first aspect of the invention and its embodiments, the device cartridge removably received in the housing, the device including a flow channel configured to, in use, fluidly connect the wick to the mouthpiece.

The features and advantages of the preceding aspects of the invention and their embodiments apply mutatis mutandis to the features and advantages of the third aspect of the invention and its embodiments.

As mentioned above, forming the chamber of a film or sheet material results in a compact and lightweight configuration of the device cartridge with fewer parts in comparison to conventional device cartridges. This in turn results in a compact and lightweight dispensing device with reduced cost and waste.

Also, as mentioned above, forming the chamber of a film or sheet material results in a ready-to-use device cartridge, which makes it straightforward for a user to use the device cartridge with the dispensing device.

The dispensing device may be an inhalation device for dispensing an inhalable aerosol.

In a preferred embodiment of the invention, the inhalation device is an electronic cigarette or a vaping device. The device cartridge may be an inhalation device cartridge as described hereinabove. The flow channel may be configured to, in use, guide aerosol from the wick to the mouthpiece. In such embodiments, the flow channel may be configured to be in sealed fluidic communication with the vaporisation chamber of the device cartridge.

The housing may include one or more contact structures configured to push against the wick so as to reinforce the wick when the device cartridge is received in the housing. The or each contact structure may be or may include, for example, a pin or a bump. This helps to maintain the shape of the wick during use in the dispensing device.

The dispensing device may include one or more guide members operable to alter or maintain a position of the heating element along the wick and/or alter or maintain a position of the wick in the chamber. This allows the heating element and/or the wick to be moved to or maintained in a desired position for the operation of the dispensing device. The movement of the heating element and/or the wick by the or each guide member may take place automatically when the device cartridge is received in the housing or may take place manually through user intervention. The or each guide member may be attached to or integrated with the housing. The or each guide member may be in the form of, for example, a gripping member, a clamping member, a pushing member or a pulling member. The or each guide member may be made of a rigid material or may be made of a compliant material (such as silicone).

The flow channel may form part of the device cartridge or the housing, or may be separate from the device cartridge and the housing. The mouthpiece may form part of the device cartridge or the housing, or may be separate from the device cartridge and the housing.

It will be appreciated that the use of the terms "first" and "second", and the like, in this patent specification is merely intended to help distinguish between similar features, and is not intended to indicate the relative importance of one feature over another feature, unless otherwise specified.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, and the claims and/or the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and all features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Preferred embodiments of the invention will now be described, by way of non-limiting examples, with reference to the accompanying drawings in which: Figures 1 to 32 show various embodiments of the invention relating to an inhalation device cartridge for use in an electronic cigarette.

The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic form in the interests of clarity and conciseness.

The following embodiments of the invention are described with reference to electronic cigarettes, but it will be appreciated that the following embodiments of the invention are applicable mutatis mutandis to other types of inhalation devices for dispensing an inhalable aerosol and to other types of dispensing devices.

Incorporation of the heating element into the device cartridge in accordance with the invention removes the problems associated with using the same heating element that is part of the electronic cigarette, such as degradation of the same heating element over time, unwanted byproducts (e.g. carbonyls) and flavour contamination due to cross-contamination or leftover residue from using different precursors with the same heating element, and variable performance over the lifetime of the heating element.

Conventionally manufacturing processes for electronic cigarette consumables are complex, costly, energy-intensive and difficult to automate. In the invention, by using thermoforming (or other suitable manufacturing process) to manufacture the casing from film or sheet material and by incorporating the wick and the heating element in the device cartridge, the resulting device cartridge has a reduced number of parts and is produced in a ready-to-use form requiring little to no assembly by a user. The manufacturing process of the device cartridge according to the invention therefore can be designed for high speed, automated production with reduced energy usage and material wastage and with the flexibility to manufacture different device cartridge designs. Additional benefits include smaller manufacturing footprint, low capital investment, reduced energy usage and reduced material wastage.

An inhalation device cartridge according to an embodiment of the invention is shown in Figure 1 and is designated generally by the reference numeral 20. The inhalation device cartridge can be used as a disposable consumable for inhalation devices. In the embodiment shown, the inhalation device cartridge 20 is used as a replaceable cartridge for an electronic cigarette.

The inhalation device cartridge 20 comprises a casing 22, a wick 24 and a heating element 26.

The casing 22 comprises a chamber, which is divided into first and second sub-chambers 28,30. The first and second sub-chambers 28,30 are arranged side-by-side in the casing 22 and are in fluidic communication with each other via an intermediate channel 32. The first and second sub-chambers 28,30 are formed by, e.g., thermoforming one of two layers of flexible polypropylene film and bonding the two layers together to create two discrete sub-chambers. Other film or sheet materials may be used in place of the polypropylene film, non-limiting examples of which are described throughout the specification. For example, the film or sheet material may be biaxially oriented polypropylene (BoPP) film, polyvinyl chloride (PVC) film, polyethylene terephthalate (PET) film, polystyrene (PS) film or polyolefin film.

Variations of the PET film include, but are not limited to, polyethylene terephthalate glycol (PETG), amorphous PET (APET), crystallized PET (CPET), recycled PET (rPET) and a laminate of PETG-APET-PETG (GAG). The choice of film or sheet material will depend on the desired mechanical properties, adherence to food safety requirements, and shelf life properties (such as oxygen barrier properties, and resilience to certain chemicals e.g. nicotine and/or acids). The first and second sub-chambers 28,30 may have different sizes to give the inhalation device cartridge 20 an asymmetric shape. In the embodiment shown, the first sub-chamber 28 is larger than the second sub-chamber 30 but may be smaller than the second sub-chamber 30 in other embodiments.

The bonding is achieved using heat sealing in this embodiment but may be achieved by other bonding means such as pressure sealing, ultrasonic welding, high frequency welding, fusing or adhesive. In other embodiments of the invention, the first and second sub-chambers 28,30 may be formed of other film or sheet material, and non-limiting examples of other film or sheet materials are described throughout the specification.

As a result of forming the chamber in the casing 22 and using film or sheet material to form the casing 22, the casing 22 has a flat face on one side and an uneven face on the other side. In other embodiments, the casing 22 may have uneven faces on both sides, i.e. the casing 22 may have three-dimensional structures on both sides.

The first sub-chamber 28 is configured as a reservoir that stores a liquid aerosol precursor, which may be selected from a group consisting of: * a vaping substance; * nicotine, a cannabinoid, cannabidiol, tetrahydrocannabinol, a psychoactive substance, a non-psychoactive substance, a nicotine-free substance and/or a derivative thereof.

The liquid aerosol precursor may be replaced by a solid or gel aerosol precursor in other embodiments.

The second sub-chamber 30 defines a vaporisation chamber 34. The second sub-chamber 30 is configured to hold the wick 24 in a bridge configuration in which the ends of the wick 24 are located and retained in respective retention channels while an intermediate portion of the wick 24 between the two ends is suspended inside the vaporisation chamber 34. The wick 24 is made of a fibrous material, such as cotton.

The wick 24 may be made of a flexible or semi-rigid material. The wick 24 is formed as a planar, or substantially planar, wick 24. Each retention channel may have a more complex shape (such as a meander shape or an arcuate shape) to improve the location and retention of the ends of the wick 24.

The configuration of the sub-chambers and the wick 24 allows the aerosol precursor to be transferred in a controlled manner from the reservoir to the vaporisation chamber 34. The vaporisation chamber 34 itself provides clearance and space for aerosol formation and collection so that the aerosol can be provided, via a dispensing device, to the consumer in a controlled manner and at a desired location. In this way aerosol deposition is limited elsewhere in the inhalation device cartridge 20 and the dispensing device.

The heating element 26 is wrapped around the suspended intermediate portion of the wick 24 inside the vaporisation chamber 34 so as to be isolated, i.e. not in contact, with the casing 22. In this way the heating element 26 is thermally isolated from the casing 22 by the wick 24. Also, attaching the heating element 26 to the wick 24 prevents the heating element 26 from coming loose inside the vaporisation chamber 34 or falling out of the vaporisation chamber 34. Since the heating element 26 is wrapped around the wick 24, the required three-dimensional structure of the heating element 26 provides the heating element 26 with structural strength. By having the heating element 26 extend along the length of the wick 24, the wick s strength and stability are improved, which in turn improves the contact between the heating element 26 and the wick 24.

Optionally, in embodiments of the invention, the wick 24 may include one or more retention features to locate or constrain the heating element 26 and retain the heating element 26 relative to the wick 24.

The heating element 26 preferably includes a resistive section, which may be shaped as a serpentine, meander or mesh section. The heating element 26 includes electrical terminals 36 which in use are connected to electrical contacts 38 of, or associated with, a power source in order to pass an electrical current through the resistive section and thereby generate heat. The bridge configuration helps to keep the wick 24 in tension so that the wick 24 stays taut when the electrical contacts 38 are brought into contact with the electrical terminals 36 of the heating element 26.

The inhalation device cartridge 20 includes a lid 40 that is arranged to seal the vaporisation chamber 34 from the outside of the casing 22. The lid 40 is preferably formed from the film or sheet material forming the flat face of the casing 22. The lid may be made of a different material in other embodiments. The provision of the lid 40 to seal the vaporisation chamber 34 from the outside of the casing 22 makes it easier to obtain an excellent seal. In use, the lid 40 is openable to provide access to the vaporisation chamber 34 and thereby provide access to the heating element 26. Opening the vaporisation chamber 34 at the flat face of the casing 22 not only enables the electrical contacts 38 to gain access to the electrical terminals 36 but also permits aerosol to be delivered to the outside of the casing 22 via the opened vaporisation chamber 34, without requiring perforation, puncturing or piercing of the uneven face of the casing 22 which may be detrimental to the structural integrity of the inhalation device cartridge 20.

As shown in Figure 2, the lid 40 may have a perforated portion around its perimeter or may be thinned (e.g. by ablation), which not only makes it easier to open the lid 40 but also provides a user with a defined way of opening the lid 40. The lid 40 can be lifted and removed in order to provide access to the vaporisation chamber 34.

As shown in Figure 3, a sticker 42 is placed over the lid 40 by adhesion of the sticker 42 to the casing 22. The sticker 42 has a tab on one of its sides. The tab can be pulled in order to peel the sticker 42 from the casing 22 so that the lid 40 in turn can be opened. The sticker 42 itself may be configured as a lid to seal the vaporisation chamber 34 from the outside of the casing 22, either independently of or in combination with the other lid 40. The sticker 42 may act as a seal of quality, freshness or authenticity.

The tab may be located at a different part of the sticker 42, such as the corner of the sticker as shown in Figure 4. The sticker 42 may be moved and adhered to a different part of the casing 22. When the inhalation device cartridge 20 is no longer in use, the sticker 42 may be moved back over the opening of the vaporisation chamber 34 in order to reseal the vaporisation chamber 34 from the outside of the casing 22. In this way the sticker 42 functions as a resealable lid. The sticker 42 may be replaced by a different sticker.

The inhalation device cartridge may form part of a pack of inhalation device cartridges in which each inhalation device cartridge is separated from the at least one other inhalation device cartridge by a tear line, a cut line or a perforation line. This allows multiple inhalation device cartridges to be manufactured, transported, stored or sold as a pack, where an individual inhalation device cartridge is detached from the pack without damaging the individual inhalation device cartridge or the rest of the pack.

The inhalation device cartridge or the pack of inhalation device cartridges may be stored inside a package, such as a box or a cardboard container, in order to protect the inhalation device cartridge or the pack of inhalation device cartridges during transport or storage.

An exemplary way of using the inhalation device cartridge 20 of the invention is described as follows, with reference to its use as a replaceable cartridge for an electronic cigarette. The electronic cigarette comprises a mouthpiece, a housing, a battery and the replaceable inhalation device cartridge 20.

The housing 44 includes a receptacle 46, a door and a flow channel 48. The housing 44 may be made of silicone, polyurethane and/or another polymer, or alternatively or additionally may be made of at least one other material. The housing 44 may include silicone, polyurethane or other polymer components to, for example, form seals. The receptacle 46 is for removably receiving the inhalation device cartridge 20. The receptacle 46 is formed in a body of the housing 44. The door is hingably attached to the body so that it can be opened and closed in order to selectively permit and block access to the receptacle 46. The flow channel 48 is provided in the body of the housing 44. The mouthpiece is positioned at the end of the flow channel 48. The mouthpiece may be integral or attached to the body of the housing 44 In alternative embodiments, the flow channel 48 may form part of the inhalation device cartridge 20 instead of the housing 44, or may be separate from the inhalation device cartridge 20 and the housing 44.

The inhalation device cartridge 20 may be inserted into the receptacle 46 via the door.

The door may be omitted in other embodiments. In some embodiments, the inhalation device cartridge 20 may be inserted into the receptacle 46 via an aperture. In other embodiments, the housing 44 may be openable (e.g. may be slideable to open) to reveal the receptacle 46 for insertion of the inhalation device cartridge 20.

The inhalation device cartridge 20 may be directly inserted into the receptacle 46. Alternatively the inhalation device cartridge 20 may be inserted in a tray or carrier which in turn is inserted into the receptacle 46.

When the inhalation device cartridge 20 is received in the housing 44 and the door is closed, the flow channel 48 is in sealing engagement with the flat face of the casing 22 around the opening of the vaporisation chamber 34, e.g. along the dashed line shown in Figure 1, in order to obtain a sealed fluidic communication with the opened vaporisation chamber 34. The sealed engagement allows the electrical contacts 38 to interface with the heating element's electrical terminals 36, allows air to enter the vaporisation chamber 34 and allows aerosol to exit the vaporisation chamber 34 in a controlled manner. Moreover, sealing off the vaporisation chamber 34 minimises deposition or condensation of aerosol elsewhere in the electronic cigarette. The flow channel 48 may include a compliant material, such as silicone, that contacts the flat face of the casing 22 in order to achieve the sealing effect.

The housing 44 may include one or more location features, such as a rod, a wall, a pin or a clip, that acts to locate the inhalation device cartridge 20 in the correct position and orientation inside the receptacle 46. Furthermore, the asymmetric shape of the inhalation device cartridge 20 helps to ensure that it is correctly positioned and oriented inside the receptacle 46. The inhalation device cartridge 20 and the receptable may be correspondingly shaped to provide a mating fit (e.g. a push fit) between the inhalation device cartridge 20 and the receptable so that the inhalation device cartridge is correctly positioned inside the receptacle 46.

Preferably the entire receptacle 46 may be sealed off from the outside of the housing 44.

The battery is stored in a compartment inside the housing 44 and is used to power the heating element 26 via electrical contacts 38 that are inserted through the opening of the vaporisation chamber 34 to come into contact with the heating element's electrical terminals 36. The flexible nature of the casing 22 and the wick 24 enables the use of rigid electrical contacts 38 to contact the heating element's electrical terminals 36.

Optionally the battery may be used to power a controller, e.g. a microcontroller, that is used to control the heating element 26.

In other embodiments of the invention, the electrical terminals 36 may be located outside the vaporisation chamber 34.

A non-limiting example of a method of using the inhalation device cartridge 20 is described as follows.

The lid 40 is opened, and if applicable the sticker 42 is peeled, so as to open the vaporisation chamber 34. This may take place before or after the inhalation device cartridge 20 is inserted into the receptacle 46. The inhalation device cartridge 20 is placed in its intended position and orientation in the receptacle 46 before closing the door. It may be necessary to remove a used inhalation device cartridge from the receptacle 46 before inserting the inhalation device cartridge 20 into the receptacle 46.

The fluidic connection between the first and second sub-chambers 28,30 allows the liquid aerosol precursor in the first sub-chamber 28 to enter the second chamber and thereby wet the wick 24. Thereafter, the liquid aerosol precursor diffuses throughout the wick 24 by way of capillary action. The heating element 26 is controlled to heat up the liquid aerosol precursor in the wick 24 to create an inhalation aerosol that emanates from the wick 24 into the vaporisation chamber 34. In this way the wick 24 and the heating element 26 together function as an atomiser to produce the inhalation aerosol from the liquid aerosol precursor.

The flow channel 48 then guides the inhalation aerosol from the vaporisation chamber 34 to the mouthpiece, so that a user may inhale the inhalation aerosol through the mouthpiece. Preferably the housing 44 includes an air conduit that is configured to connect the outside of the housing 44 to the vaporisation chamber 34. The presence of the air conduit assists the flow of the inhalation aerosol from the wick 24 to the mouthpiece by forming an air path comprising the air conduit, the vaporisation chamber 34, the flow channel 48 and the mouthpiece, whereby air can flow from the outside of the housing 44, into the air conduit, through the vaporisation chamber 34, through the flow channel 48 and through the mouthpiece in that order when a user sucks on the mouthpiece.

Once the liquid aerosol precursor is used up, the inhalation device cartridge 20 can be removed from the receptacle 46 and replaced by a new inhalation device cartridge. If the user wants to stop using the electronic cigarette but the liquid aerosol precursor is not used up, the user may remove the inhalation device cartridge 20 from the receptable and reseal the vaporisation chamber 34 using the sticker 42 or another sticker.

A non-limiting example of a method of manufacturing the inhalation device cartridge 20 is described as follows, with reference to polypropylene film as the film or sheet material. It will be understood that other thermoformable materials may be used in place of the polypropylene film.

A plurality of wells is formed in a first layer of the polypropylene film, where each pair of wells correspond to the first and second sub-chambers 28,30 of an individual inhalation device cartridge 20. The wells may be formed using thermoforming, such as vacuum forming or pressure forming.

Liquid aerosol precursor is dispensed into each well corresponding to the first sub-s chamber 28 of an individual inhalation device cartridge 20. A respective wick 24 is placed in each well corresponding to the second sub-chamber 30 of an individual inhalation device cartridge 20. Prior to each wick 24 being placed in the respective well, each wick 24 is assembled with a respective heating element 26. Alternatively each heating element 26 may be added to the respective wick 24 after the wick 24 is placed in the respective well.

A second layer of the polypropylene film is then placed over the first layer of the polypropylene firm. The two layers of the polypropylene film are then bonded together by heat sealing, thus forming the first and second sub-chambers 28,30. The first layer of the polypropylene film defines the uneven face of the casing 22. The second layer of the polypropylene film defines the flat face of the casing 22.

Shapes or symbols may be moulded in the wells as part of the thermoforming process. The shapes or symbols may include information, such as tactile warning shapes (e.g. triangles) and other mandatory warnings. Such information may indicate the presence of a hazardous substance, e.g. nicotine, in the casing 22.

A lid 40 is formed in the flat face of the casing 22 and over the vaporisation chamber 34 by cutting a perforation or tear line (e.g. using a die or a laser) defining a perimeter of the lid 40 and/or thinning a section of the flat face of the casing 22 and over the vaporisation chamber 34 (e.g. by ablation). If applicable, a sticker 42 is placed over the lid 40 and adhered to the flat face of the casing 22 of each inhalation device cartridge 20.

A die is then used to create perforation lines in the bonded layers of the polypropylene film to produce a pack of inhalation device cartridges in which the inhalation device cartridges are detachably attached from each other by the perforation lines. Alternatively, the die may be used to cut through the bonded layers of the polypropylene film to produce individual inhalation device cartridges that are detached from each other. Alternatively a laser may be used in place of the die. The laser may be used to score the surface to create tear lines instead of penetrating the surface to create the perforation lines. Other ways of creating tear lines, cut lines or perforation lines in the bonded layers of the polypropylene film may be used.

Die-cutting, laser-cutting or other cutting or marking techniques may be used to add perforations, notches, cut-outs or marks that provide information about the inhalation device cartridge 20. The information may be directed to a consumer or a manufacturer, and may indicate the type, flavour and/or strength of liquid aerosol precursor used and/or the batch code and/or the date of manufacture and/or other legal/market requirements.

The foregoing manufacturing steps permit the use of a single production line for end-to-end manufacture of the inhalation device cartridge 20, particularly due to the formation of the first and second sub-chambers 28,30 in the film or sheet material and due to the reduced number of parts of the inhalation device cartridge 20. The single production line comprises a thermoforming machine, a liquid aerosol precursor dispensing station, a wick 24 placement machine, a heat sealing apparatus and a die cutter. As a result, high speed and cost-effective production in a single location is possible.

In contrast, conventional inhalation device cartridges require multiple manufacturing lines that include metal die casting, lathes, plastic injection moulding and so on. These require large and specialist manufacturing facilities that are usually distributed around the world, thus requiring expensive and time-consuming transport of parts between manufacturing locations.

Optionally the two layers of flexible polypropylene film may be bonded at a section between the first and second sub-chambers 28,30 to form a frangible seal separating the first and second sub-chambers 28,30. Preferably the bond between the layers of polypropylene film forming the frangible seal is weaker than the bond between the layers of polypropylene film forming the first and second sub-chambers 28,30, so that the frangible seal can be broken while leaving the first and second sub-chambers 28,30 intact.

The purpose of the frangible seal is to prevent accidental leakage or displacement of the liquid aerosol precursor from the first sub-chamber 28 prior to the point of intended use and also to prevent ingress of outside air, moisture or water into the first sub-chamber 28 prior to the point of intended use. The latter is particularly important when the liquid aerosol precursor is hygroscopic. The frangible seal is designed to be breakable so that a fluid connection is established between the first and second sub-chambers 28,30, which allows fluid to be exchanged between the first and second sub-chambers 28,30 via a fluid path provided by the broken frangible seal. The frangible seal may be formed as a single-use seal which after breakage cannot be resealed, or a resealable seal.

Separating the liquid aerosol precursor and the wick 24 in the first and second sub-chambers 28,30 respectively allows the wick 24 to be kept dry before the frangible seal is broken. It will be appreciated that the wick 24 may be stored in the second sub-chamber 30 in a pre-wetted state. This beneficially not only provides control of the egress of the inhalation aerosol from the inhalation device cartridge 20 but also allows the dry wick 24 to absorb any unexpected leakage of liquid aerosol precursor from the first sub-chamber 28 in the event of damage or untimely breakage of the frangible seal.

When the inhalation device cartridge 20 includes the frangible seal, the door may function as a seal breaker to break the frangible seal. In particular, the door and the receptacle 46 may be shaped and dimensioned so that the door itself when closed is capable of squeezing the first sub-chamber 28 to apply pressure to the first sub-chamber 28, thus building up internal pressure inside the first sub-chamber 28. Once sufficient internal pressure is built up inside the first sub-chamber 28, the internal pressure pushes outward against the layers of polypropylene film to the extent that the bond at the frangible seal starts to weaken. This eventually leads to separation of the layers of polypropylene film at the frangible seal and thereby breakage of the frangible seal. In this way the seal breaker provides a controlled way of breaking the frangible seal. In embodiments of the invention, the door may be deformable so that the door when closed may be pushed to apply pressure to the first sub-chamber 28 in order to break the frangible seal, or the seal breaker may take the form of a protrusion formed on an inner surface of the door.

Configuring the inhalation device cartridge 20 in accordance with the invention not only enables assembly of the inhalation device cartridge 20 from one side of the casing 22 by inserting the internal components into wells in the thermoformed layer and bonding the other layer over the thermoformed layer but also allows the three-dimensional structure of the casing 22 to remain intact and thereby provide the inhalation device cartridge 20 with structural integrity. In addition the configuration of the inhalation device cartridge 20 in accordance with the invention makes it easier to open the vaporisation chamber 34 without damaging the three-dimensional structure of the casing 22 and the internal components (thus protecting the heating element 26 and wick 24) and makes it easier for a dispensing device to form a sealed fluidic connection with the inhalation device cartridge 20 via the vaporisation chamber 34.

Additional or alternative features of the invention are described as follows. Two or more of these features may be used in combination unless such features are incompatible.

The electrical contacts 38 associated with the power source are pressed onto the heating element's electrical terminals 36. The heating element 26 and/or the wick 24 may be configured to have additional stiffness in order to enable the heating element's electrical terminals 36 maintain contact with the electrical contacts 38 associated with the power source. Non-limiting examples are outlined below and elsewhere in the specification.

The inhalation device cartridge may include one or more reinforcement members combined with the wick 24 and/or the heating element 26. The or each reinforcement member acts to maintain the shape of the wick 24 and/or heating element 26 by, for example, increasing the strength or stiffness of the wick 24 and/or the heating element 26. For example, one or more additional materials (e.g. in the form of a lamina) may be added within the wick 24, on one side of the wick 24 or on both sides of the wick 24 in order to add stability and rigidity to the wick 24. This improves the resistance of the wick 24 to deflection, buckling and/or stretching. The or each material may extend transversely or longitudinally along the wick 24. The or each material may be or may include a shim, cotton, ceramic, polymer, plastic, wood, cellulose, paper, card or metal.

Preferably the or each material is a temperature resistant material. One or more materials may be added to the wick 24 by stitching, stapling or another way of fastening.

Figure 5 shows part of the housing 44 applying a pushing force to the ends of the wick 24 via the flat face of the casing 22. This helps to keep the wick 24 under tension so that it remains taut when the electrical contacts 38 are brought into contact with the heating element's electrical terminals 36. The housing 44 may include other features, such as protrusions, pins or bumps, that are capable of applying a pushing force to the wick 24 in order to keep the wick 24 taut.

Figure 6 shows an alternative wick 24 which is folded into two so that the heating element's legs are sandwiched between the folded layers of the wick 24. This helps to constrain the position of the heating element 26 on the wick 24 and inside the vaporisation chamber 34 while adding tensile strength and rigidity to the wick 24. The heating element 26 also remains thermally isolated from the casing 22. The well corresponding to the second sub-chamber 30 may include a depression 50 that functions as a support structure inside the vaporisation chamber 34 to support the wick 24.

Figure 7 shows an alternative heating element 26 that is inverted with respect to the wick 24 so that its electrical terminals 36 face the uneven face of the casing 22 instead of the flat face of the casing 22. In this configuration, the electrical contacts 38 extend through the well corresponding to the second sub-chamber 30 so that the electrical contacts 38 are inside the vaporisation chamber 34. This allows the electrical contacts 38 to be in contact with the heating element's electrical terminals 36. The electrical contacts 38 may have sharp ends to puncture or pierce through the well corresponding to the second sub-chamber 30 and into the vaporisation chamber 34. Preferably the electrical contacts 38 extend through predesignated points in the well corresponding to the second sub-chamber 30. A lid 40 or sticker 42 may be used to indicate the predesignated points. The electrical contacts 38 may puncture or pierce through the lid 40 or sticker 42 at the predesignated points.

By having the electrical contacts 38 extend through the well corresponding to the second sub-chamber 30, the electrical contacts 38 push the wick and heating element assembly towards the housing 44 that presses against the flat face of the casing 22. This constrains the wick 24 and the heating element 26 in order to improve the contact between the electrical contacts 38 and the heating element's electrical terminals 36, which can be further improved by forming the housing 44 of a compliant material.

In addition, the electrical terminals 36 and the electrical contacts 38 are located on one side of the wick 24 that faces the uneven face of the casing 22, while the resistive section (shown as mesh sections) of the heating element 26 is located on the opposite side of the wick 24 that faces the flat face of the casing 22. This not only provides an improved air path with reduced air flow interference by the electrical contacts 38 but also allows the inhalation device cartridge to be received in the receptacle 46 of the housing 44 with the flat face of the casing 22 oriented towards the user.

Figure 8 shows an embodiment of the inhalation device cartridge in which the second sub-chamber 30 is configured to hold the wick 24 in a cantilever configuration. One end of the wick 24 is located and retained in a retention channel while the opposite, free end of the wick 24 is suspended inside the vaporisation chamber 34. This allows the first sub-chamber 28 to expand its footprint to take up the space in the casing 22, which was previously occupied by the wick 24 in Figures 1 to 7. In the embodiment shown, the first sub-chamber 28 is formed as an L-shaped sub-chamber. This in turn permits a reduction in the depth of the well corresponding to the first sub-chamber 28 to reduce the overall size of the cartridge. In addition, a shorter wick 24 can be used, and the sealing footprint for bonding the two layers of film or sheet material to form the casing 22 can also be reduced.

The asymmetric design of the casing 22 in Figure 8, in particular the shape of the first sub-chamber 28, applies mutatis mutandis to other wicks 24 supported in the second sub-chamber 30 in alternative configurations, such as a bridge configuration.

Figure 9 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 8 except that the inhalation device cartridge of Figure 9 includes a support structure in the form of a silicone cylinder 52. The silicone cylinder 52 is placed inside the vaporisation chamber 34 so that the silicone cylinder 52 is located between the uneven face of the casing 22 and the wick and heating element assembly. The silicone cylinder 52 is oriented so that the wick and heating element assembly is in direct contact with the silicone cylinder 52 along the height of the silicone cylinder 52. The direct contact between the silicone cylinder 52 and the wick and heating element assembly reinforces the wick and heating element assembly by providing support and compression resistance.

In other embodiments, the support structure may have a different shape such as a cuboid, a prism or a polyhedron, instead of cylindrical. The support structure may be solid instead of tubular. The support structure may be configured as an extrusion, foam or sponge. The support structure may be made of a different thermally insulating material. The support structure may be replaced by multiple support structures.

Figure 10 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 9 except that, in the inhalation device cartridge of Figure 10, the silicone cylinder 52 is oriented so that the wick and heating element assembly is in direct contact with a flat end face of the silicone cylinder 52.

Figure 11 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 10 except that, in the inhalation device cartridge of Figure 11, the second sub-chamber 30 is configured to hold the wick 24 in a bridge configuration in which the ends of the wick 24 are located and retained in respective retention channels while an intermediate portion of the wick 24 between the two ends is suspended inside the vaporisation chamber 34.

In the foregoing embodiments, a thickness of the wick 24 extends perpendicularly to the flat face of the casing 22.

Figure 12 shows an embodiment of the inhalation device cartridge in which a thickness of the planar wick 24 extends parallelly to the flat face of the casing 22. The heating element's electrical terminals 36 are mounted along the edge of the wick 24 that faces the flat face of the casing 22. The heating element 26 is preferably pinched or otherwise clamped onto the wick 24 to maximise contact between the heating element 26 and the wick 24. This configuration improves the compression resistance of the wick and heating element assembly, which is particularly useful when the electrical contacts 38 associated with the power source are brought into contact with the heating element's electrical terminals 36. In addition, this configuration isolates the heating element 26 from the casing 22 on all sides and also allows the width of the casing 22 to be reduced.

Figure 13 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 12 except that the casing 22 of the inhalation device cartridge of Figure 13 includes an additional first sub-chamber 28. The first sub-chambers 28 are symmetrically arranged on opposite sides of the second sub-chamber 30 so as to provide a symmetrical inhalation device cartridge.

Figure 14 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 1 except that, in the inhalation device cartridge of Figure 14, the heating element 26 is not mounted on the wick 24. Instead the inhalation device cartridge includes a support member 54 attached to the casing 22 and configured to support the heating element 26 to be in direct contact with the wick 24. In particular, the heating element 26 includes a pair of support legs that are attached to the support member 54. In this way the heating element 26 is configured as a cantilever that is mounted, via the support member 54, on the casing 22. This rigidly constrains the heating element 26 in the inhalation device cartridge while keeping the heating element 26 thermally isolated from the casing 22, without adversely affecting the overall structural integrity of the casing 22.

Figure 15 shows an alternative embodiment of the inhalation device cartridge. Instead of having a rectangle or square shape, the casing 22 is shaped as a rectangle with semicircles at opposite ends of the rectangle (which is also known as a stadium shape). The first sub-chamber 28 is located at a first end of the casing 22, while the second sub-chamber 30 is located at a second end of the casing 22. The wick 24 is held by the second sub-chamber 30 in a bridge configuration in which the ends of the wick 24 are located and retained in respective retention channels while an intermediate portion of the wick 24 between the two ends is suspended inside the vaporisation chamber 34. The heating element 26 is arranged in the vaporisation chamber 34 to extend in a direction perpendicular to an extension direction of the wick 24 between the retention channels. Support members 54 are attached to opposite support legs of the heating element 26 so that the heating element 26 is supported by the support members 54 in a bridge configuration.

Preferably the or each support member is made of a thermally insulating material such as silicone, ceramic, mica, fibre, cotton, wood, cellulose, silicone or polyurethane. The or each support material may be covered (e.g. dip-coated, enamelled or overmoulded) by a thermally insulating material (e.g. silicone, ceramic, mica, fibre, cotton, wood, cellulose, silicone or polyurethane). The support legs may be wrapped by a thermally insulating material such as silicone or polyurethane. The heating element 26 may be further supported by a support structure inside the vaporisation chamber 34, e.g. as shown in Figures 9 to 11.

Figure 16 shows an embodiment of the inhalation device cartridge in which the first and second sub-chambers 28,30 are configured to hold the wick 24 in a cantilever configuration. The wick 24 extends through both the first and second sub-chambers 28,30. In particular, one end of the wick 24 is located and retained in a retention channel next to the vaporisation chamber 34 while the opposite, free end of the wick 24 is suspended inside the first sub-chamber 28. The heating element 26 is mounted on an intermediate portion of the wick 24 that is suspended inside the vaporisation chamber 34. In this way, part of the wick 24 is located inside the first sub-chamber 28 containing the liquid aerosol precursor, which allows the wick 24 to stay wetted and thereby aids the transfer of the liquid aerosol precursor into the vaporisation chamber 34.

To seal off the vaporisation chamber 34 from the outside of the casing 22, a removable lid 40 or sticker 42 may be used. In use, the flow channel 48 may be in sealing engagement with the flat face of the casing 22 around the opening of the vaporisation chamber 34 along the dashed line in Figure 16. Exemplary features of the lid 40 and sticker 42 are described throughout the specification. After the vaporisation chamber 34 is opened, electrical contacts 38 may be brought into contact with the heating element's electrical terminals 36.

In other embodiments, the first and second sub-chambers 28,30 may be configured to hold the wick 24 in a bridge configuration. In particular, one end of the wick 24 is located and retained in a retention channel next to the vaporisation chamber 34 while the opposite end of the wick 24 is located and retained in another retention channel next to the first sub-chamber 28, so that intermediate portions of the wick 24 are suspended inside the vaporisation chamber 34 and the first sub-chamber 28 respectively.

Figure 17 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 16 except that, in the inhalation device cartridge of Figure 17, the heating element 26 is inverted with respect to the wick 24 so that its electrical terminals 36 face the uneven face of the casing 22 instead of the flat face of the casing 22.

Similarly to the embodiment of Figure 7, the electrical contacts 38 extend through the well corresponding to the second sub-chamber 30 so that the electrical contacts 38 are inside the vaporisation chamber 34. The features of the heating element 26 and the electrical contacts 38 of the embodiment of Figure 7 apply mutatis mutandis to the embodiment of Figure 17.

Figure 18 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 16 except that, in the inhalation device cartridge of Figure 18, a thickness of the wick 24 extends parallelly, instead of perpendicularly, to the flat face of the casing 22.

Figure 19 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 18. In addition, the associated electronic cigarette includes guide members 56 that grip the electrical terminals 36 of the heating element 26 so that the guide members 56 are operable to alter a position of the heating element 26 to a desired position along the wick 24. The guide members 56 may be made of a thermally insulating material such as silicone. Preferably the guide members 56 are grip members. Optionally the guide members 56 may be configured as electrical contacts associated with the power source. The guide members 56 may be attached to or integrated with the housing 44 of the dispensing device.

Figure 20 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 18 except that, in the inhalation device cartridge of Figure 20, the vaporisation chamber 34 can be opened on both sides of the casing 22. That is to say, a first opening 58 of the vaporisation chamber 34 is located on the flat face of the casing 22, and a second opening 60 of the vaporisation chamber 34 is located on the uneven face of the casing 22. Removable lids 40 or stickers 42 may be used to seal off the vaporisation chamber 34 from the outside of the casing 22.

The electrical contacts 38 associated with the power source may be brought into contact with the heating element's electrical terminals 36 through the first or second opening 58,60. The electrical contacts 38 may be brought into contact with the heating element's electrical terminals 36 on either side or both sides of the wick 24. The housing 44 may include one or more location features, such as a rod, a wall, a pin or a clip, that can be inserted into either opening 58,60 in order to interface with the wick 24 and/or the heating element 26.

Figure 21 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 16 except that the inhalation device cartridge of Figure 21 excludes the second sub-chamber 30 and thereby excludes the vaporisation chamber 34. Therefore, part of the wick 24 extends out of the casing 22. The heating element 26 is mounted on the part of the wick 24 that extends out of the casing 22.

Preferably the inhalation device cartridge includes a cover 62 covering the part of the wick 24 extending out of the casing 22 in order to protect the wick 24 from damage or contamination prior to use. In use, the cover 62 may be torn off, snapped off or otherwise detached from the casing 22 to uncover the part of the wick 24 extending out of the casing 22. The cover 62 may be made of the same material as the casing 22 and thereby may be manufactured together with the casing 22. Alternatively the cover 62 may be made of a different material.

Figure 22 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 21 except that, in the inhalation device cartridge of Figure 22, the heating element 26 includes an elongated limb portion 64 that extends along the wick 24 and into the first sub-chamber 28. The provision of the elongated limb portion 64 provides the heating element 26 with additional strength to maintain the structural integrity and alignment of the wick and heating element assembly.

Figure 23 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 1 except that, in the inhalation device cartridge of Figure 23, the casing 22 includes a hinged portion 66 between the first and second sub-chambers 28,30. The casing 22 further includes two notches 68 at the edge of the casing 22 to indicate the location of the hinged portion 66. The hinged portion 66 permits the deformation of the casing 22 (in this case bending) without damaging the first and second sub-chambers 28,30 and the wick and heating element assembly.

Figure 24 shows the insertion of the inhalation device cartridge of Figure 23 into a housing 44 of an exemplary electronic cigarette. Initially the part of the casing 22 containing the second sub-chamber 30 is inserted in a vertical orientation in the housing 44, preferably slid into a receptacle 70 in the housing 44 as shown in Figure 24. The door 72 of the housing 44 is then closed to bend the casing 22 by way of the hinged portion. When the door 72 is closed, the casing 22 is bent at a 900 angle, with both sub-chambers received in the housing 44. This allows for a reduction in the overall size of the electronic cigarette.

Figure 25 shows an embodiment of the inhalation device cartridge in which the casing 22 excludes the intermediate channel 32 that fluidly connects the first and second sub-chambers 28,30. The wick 24 is held by the second sub-chamber 30 in a bridge configuration, examples of which are described throughout the specification. The heating element 26 is wrapped around an intermediate portion of the wick 24 that is suspended inside the vaporisation chamber 34. The heating element 26 may be mounted on the casing 22 via its support legs which themselves are supported by support members preferably made of thermally insulating material.

In use, the casing 22 can be folded so that the first and second sub-chambers 28,30 overlap each other and so that the wick and heating element assembly faces the first sub-chamber 28. Either one of the first and second sub-chambers 28,30 may be positioned above the other of the first and second sub-chambers 28,30. Preferably the casing 22 includes a weakened portion, such as a hinged portion, between the first and second sub-chambers 28,30 to aid the bending of the casing 22.

When the casing 22 is folded as shown in Figure 25, the support legs also function as the heating element's electrical terminals 36. For example, the folded casing 22 may be inserted into a housing 44 of an electronic cigarette so that the heating element's electrical terminals 36 are brought (e.g. slid) into mating contact with the electrical contacts 38 associated with the power source.

Figure 26 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 25 except that, in the inhalation device cartridge of Figure 26, the casing 22 includes the intermediate channel 32 that fluidly connects the first and second sub-chambers 28,30.

In use, the casing 22 can be folded so that the first and second sub-chambers 28,30 overlap each other and so that the wick and heating element assembly faces away from the first sub-chamber 28. That is to say, the casing 22 of the inhalation device cartridge of Figure 26 is folded in the opposite direction to the folding direction of the casing 22 of the inhalation device cartridge of Figure 25. This makes it easier for the electrical contacts 38 associated with the power source to be brought into contact with the heating element's electrical terminals 36.

Either one of the first and second sub-chambers 28,30 may be positioned above the other of the first and second sub-chambers 28,30. Preferably the casing 22 includes a weakened portion, such as a hinged portion, between the first and second sub-chambers 28,30 to aid the bending of the casing 22.

Preferably the well corresponding to the first sub-chamber 28 includes a receptacle 74 to receive the well corresponding to the vaporisation chamber 34 when the casing 22 is folder. This allows the capacity of the reservoir to be increased without having to also increase the overall size of the folded casing 22.

Figure 27 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 25 except that, in the inhalation device cartridge of Figure 27, the part of the casing 22 containing the second sub-chamber includes a pair of shoulders 76 formed on opposite sides of the vaporisation chamber 34. When the casing 22 is folded, the shoulders 76 abut the part of the casing 22 containing the first sub-chamber 28 to improve the flow path between the first and second sub-chambers 28,30. Alternatively the shoulders 76 may be formed on the part of the casing 22 containing the first sub-chamber 28, so that the shoulders 76 abut the part of the casing 22 containing the second sub-chamber 30 when the casing 22 is folded.

Figure 28 shows an embodiment of the inhalation device cartridge which is similar to the inhalation device cartridge of Figure 27 except that, in the inhalation device cartridge of Figure 28, the part of the casing 22 containing the second sub-chamber 30 extends beyond the opposing part of the casing 22 containing the first sub-chamber 28 when the casing 22 is folded. In addition, the wick and heating element assembly is also extended beyond the opposing part of the casing 22 containing the first sub-chamber 28 when the casing 22 is folded. Configuring the inhalation device cartridge in this manner simplifies the manner of bringing the electrical contacts 38 into contact with the heating element's electrical terminals 36, improves the contact between the electrical contacts 38 and the heating element's electrical terminals 36 and increases the stability of the inhalation device cartridge in the housing 44 of the electronic cigarette.

Figure 29 shows the insertion of an inhalation device cartridge, such as the one shown in Figure 26, into a housing 44 of an exemplary electronic cigarette. The housing 44 includes retention features 78 moulded into the housing 44 to aid the placement of the inhalation device cartridge and prevent accidental release. In the embodiment shown, the retention features 78 are configured to receive flat edges at the end of the part of the casing 22 containing the vaporisation chamber 34. Preferably the retention features 78 are sized to provide an interference fit between the retention features and the flat sections of the casing 22. The retention features may be in the form of, but not limited to, clips or clamps.

The housing 44 further includes a flow channel 48 that is aligned with the vaporisation chamber 34 in order to fluidly connect the wick 24 to the mouthpiece.

Figure 30 shows an embodiment of the inhalation device cartridge and electronic cigarette which is similar to the embodiment of Figure 29 except that, in the embodiment of Figure 30, the housing 44 further includes additional retention features 80 for receiving flat edges along the sides of the casing 22. Figure 31 illustrates a step-by-step process of inserting the inhalation device cartridge into the electronic cigarette. Initially the casing 22 is unfolded, and the flat edges at the end of the part of the casing 22 containing the vaporisation chamber 34 are inserted into the retention features 78, as shown in Figure 31(a). The casing 22 is then folded in the sequence of Figure 31(b) to Figure 31(c) to Figure 31(d) to Figure 31(e). In Figure 31(d), the part of the casing 22 containing the vaporisation chamber 34 is laid flat in the housing 44, and the flat edges along the sides of the casing 22 are inserted into the additional retention features 80. In Figure 31(e), the folding of the casing 22 is completed.

Figure 32 shows an example of a hinged portion 82 that can be included in the casing 22 in order to enable bending or folding of the casing 22. The hinged portion 82 comprises grooves formed in the body of the casing 22. These grooves can be used as part of the intermediate channel 32 that fluidly connects the reservoir to the vaporisation chamber 34.

It will be appreciated that any of the foregoing embodiments may include a removable lid 40 or sticker 42 to seal a chamber or sub-chamber 28,30 from the outside of the casing 22 to prevent contamination.

The listing or discussion of an apparently prior-published document or apparently prior-published information in this specification should not necessarily be taken as an acknowledgement that the document or information is part of the state of the art or is common general knowledge.

Preferences and options for a given aspect, feature or parameter of the invention should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention.

Claims

CLAIMS1. A device cartridge comprising a casing, a wick and a heating element, the casing formed of film or sheet material, the casing comprising a chamber, wherein the chamber defines a reservoir for storing a precursor or ingredient, the chamber holds the wick, and the heating element is arranged in the casing to, in use, enable heating of the wick by the heating element.
2. A device cartridge according to Claim 1 wherein the heating element is in direct contact with the wick.
3. A device cartridge according to any one of the preceding claims wherein the chamber includes first and second sub-chambers, wherein the first sub-chamber defines the reservoir for storing a precursor or ingredient, the second sub-chamber defines a vaporisation chamber, and the wick and/or the heating element are at least partially arranged in the second sub-chamber.
4. A device cartridge according to Claim 3 wherein the wick and/or the heating element are at least partially arranged in the first and second sub-chambers.
5. A device cartridge according to Claim 3 or Claim 4 wherein at least part of the wick is suspended inside the vaporisation chamber.
6. A device cartridge according to any one of Claims 3 to 5 including a lid that is arranged to close off the vaporisation chamber from the outside of the casing, wherein the lid is openable to provide access to the vaporisation chamber.
7. A device cartridge according to Claim 6 wherein the lid is arranged to seal the vaporisation chamber from the outside of the casing.
8. A device cartridge according to Claim 6 or Claim 7 wherein the lid is a resealable lid.
9. A device cartridge according to any one of Claims 6 to 8 wherein the lid includes a weakened portion by which the lid is openable.
10. A device cartridge according to any one of Claims 6 to 9 wherein the lid is formed of film or sheet material.
11. A device cartridge according to any one of the preceding claims including at least one retention structure configured to locate and retain a position of the wick relative to the chamber.
12. A device cartridge according to any one of the preceding claims wherein the heating element is combined with the wick to isolate the heating element from the casing.
13. A device cartridge according to any one of the preceding claims including one or more support members attached to the casing, wherein the or each support member is configured to support the heating element and/or the wick so as to isolate the heating element and/or the wick from the casing.
14. A device cartridge according to Claim 13 wherein the or each support member is made from a thermally insulating material.
15. A device cartridge according to any one of the preceding claims including one or more reinforcement members combined with the wick and/or the heating element.
16. A device cartridge according to any one of the preceding claims including one or more support structures inside the chamber, wherein the or each support structure is in direct contact with the wick so as to reinforce the wick.
17. A device cartridge according to any one of the preceding claims wherein the wick is planar, and wherein a thickness of the planar wick extends perpendicularly to a flat face of the casing.
18. A device cartridge according to any one of Claims 1 to 16 wherein the wick is planar, and wherein a thickness of the planar wick extends parallelly to a flat face of the casing.
19. A device cartridge according to any one of the preceding claims wherein part of the wick is arranged to extend out of the casing.
20. A device cartridge according to Claim 19 including a cover covering the part of the wick extending out of the casing, wherein the cover is operable to uncover the part of the wick extending out of the casing.
21. A device cartridge according to any one of the preceding claims including one or more electrical contacts inside the chamber, wherein the or each electrical contact is in electrical contact with the heating element.
22. A device cartridge according to any one of the preceding claims wherein the film or sheet material is thermoformed film or sheet material.
23. A device cartridge according to any one of the preceding claims wherein the casing includes one or more weakened sections by which the casing may be bent or folded.
24. A device cartridge according to any one of the preceding claims wherein the device cartridge is an inhalation device cartridge, and the reservoir is configured for storing an aerosol precursor.
25. A kit of parts for a device cartridge, the kit of parts comprising a casing, a wick and a heating element, the casing formed of film or sheet material, the casing comprising a chamber, wherein the chamber defines a reservoir for storing a precursor or ingredient, wherein the casing, the wick and the heating element are combinable to form the device cartridge according to any one of the preceding claims.
26. A dispensing device comprising a mouthpiece, a housing and a replaceable device cartridge, the device cartridge in accordance with any one of the preceding claims, the device cartridge removably received in the housing, the device including a flow channel configured to, in use, fluidly connect the wick to the mouthpiece.
27. A dispensing device according to Claim 26 wherein the dispensing device is an inhalation device for dispensing an inhalable aerosol, the device cartridge is an inhalation device cartridge in accordance with Claim 24, and the flow channel is configured to, in use, guide aerosol from the wick to the mouthpiece.
28. A dispensing device according to Claim 26 or Claim 27 when either claim is dependent from Claim 3, wherein the flow channel is configured to be in sealed fluidic communication with the vaporisation chamber of the device cartridge.
29. A dispensing device according to any one of Claims 26 to 28 wherein the housing includes one or more contact structures configured to push against the wick so as to reinforce the wick when the device cartridge is received in the housing.
30. A dispensing device according to any one of Claims 26 to 29 including one or more guide members operable to alter or maintain a position of the heating element along the wick and/or alter or maintain a position of the wick in the chamber.